Assemblies Unlimited, Inc.

Club Packs

Designing and the packaging of “Club Packs” is a specialty of Assemblies Unlimited, and it is recommended that you only work with contract packaging companies who are familiar with Club Store requirements.

Club packaging specifications have been created by Costco, Sam’s Club, and BJ’s, to name a few, and their spontaneous marketing managers make the bull’s eye a moving target for consumer goods manufacturers when it comes to selecting the proper packaging for the Club Store shopper.

We are familiar with the latest trends of these big-box merchandisers and can help you from the design level and up when it comes to the food packaging solution that will maximize your sales.

Club Stores require volume selling, and there are still several design options when contemplating the best way to package your goods while meeting the store guidelines.  These include PDQ trays, large format trap blister packaging, twin packs, multi-packs, value packs, shrink wrapping, date and lot coding, registered print bundle wrapping, stretch wrapping, clam shell packaging, and more.

We can manage your club store packaging project full turnkey, supporting front-end package design, all material sourcing, and complete project management.

Assemblies Unlimited can pack anything you require. We will work alongside you and help you build your packaging specification for your club pack project.  Thru experience and sensitivity to deadlines, we will guarantee a quick turnaround and help you avoid costly packaging mistakes during the packaging phase of your important project.

A relatively new trend in large format blister card packaging for the big box stores is “Cold Sealing.”  This is where a customer PVC blister is “trapped” between 2 cards made of fiber, but heat is not required for the 2 cards to seal together.  Cycle times can be reduced by utilizing a cold seal card but it can present other limitations in proper sourcing, longer lead times, and higher costs.  Assemblies Unlimited has the resources and capabilities to handle conventional blister card heat sealing or this newer cold seal process on high-speed machinery, all as required.

Club Packs are recognized by PDQ-style corrugated trays, which typically have angled sides and an open front for easy access by the shopper. These open PDQ trays as they are called, are often direct-printed with customer-supplied artwork and then designed with an “auto-bottom” for swift assembly during the final phase of case packing. The completed trays are then stacked in an efficient pallet pattern to allow the consumer to “shop” anywhere from 2 to 4 of the sides according to the Club Store packaging specification.

Assemblies Unlimited can consult with you with proprietary packaging software which uses a 3D model to optimize the pallet cube, so all parties know how many units (Club Packs) will fit on each pallet. Truckload quantities can then be calculated, so a marketing manager knows the loaded cost of his deliverables from dock to stock.

Let Assemblies Unlimited design, source and assemble your next Club Pack for Sams, Costco, or any other Club Store.

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Our typical minimum quantity is 25,000 per SKU per run.

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We saved enormous time and capital!

As a startup in the international food business, now selling containers of products to Asia, we found Jim DeKosta and his team to serve us not only as fine and careful partners, but also as mentors: We saved enormous time and capital by relying on their expertise and experience, as opposed to having to learn everything in the highly specialized and constantly-morphing packaging arena on our own. It's essential to have a good and deep team, and great partners –– and Jim and his colleagues fulfill those roles particularly well for us. So grateful for them...

Bruce Weiss
Tenacity Partners, Inc.

Perfect packs and boxes every time!

We've been working with AUI for years - Randy, Andrea, and the Team always know how to help us navigate sticky situations! We make Caffeine Gummies, they're absolutely amazing, but sometimes they have a mind of their own and like to cause a bit of trouble during packing. Never fazes them - perfect packs and boxes every time. Love working together, will for a long time to come. Thank you for all you do!

John Pinelli
Punch'd Energy